DAIHATSU TYPE M5S Series Manual Transmission 9233

SECTION INDEX
SECTION NAME SECTION
GI
TYPE M5S Series
GENERAL INFORMATION
MANUAL TRANSMISSION MT
Manual Transmission
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NO. 9721-ME
TO INDEX GI
GENERAL INFORMATION
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IMPORTANT SAFETY NOTICE ...................... GI–2

WARNINGS, CAUTIONS AND NOTES ...... GI–2
HOW TO USE THIS MANUAL ........................ GI–4
CONTENTS OF EXPLANATION ................ GI–4
ABBREVIATION CODES ............................... GI–6
GENERAL SERVICE INSTRUCTION ............ GI–7
sGI00001-00000
GI–2
IMPORTANT SAFETY NOTICE

The vehicle is a machine comprising a great number of parts. Basically speaking, the vehicle is po-
tentially hazard. However, one can handle it safely if he has the required knowledge.
Correct service methods and repair procedures are very vital for assuring not only the safety and re-
liability of a vehicle, but also the safety of service personnel concerned.
The methods and procedures contained in this manual describe in a general way the techniques
which the manufacturer has recommended. Thus, they will contribute to ensuring the reliability of
the products. The contents of the servicing operations come in a wide variety of ways. Moreover,
techniques, tools and parts necessary for each operation are different widely from each other.
This manual does not cover all details of techniques, procedures, parts, tools and handling instruc-
tions which are necessary for these operations, for such coverage is impossible. Hence, any one
who obtains this manual is expected first to make his responsible selection as to techniques, tools
and parts which are necessary for servicing the vehicle concerned properly. Furthermore, he must
assume responsibility for his actions in connection with his own safety.
Therefore, one should not perform any service if he is not capable of making responsible selection
and/or if he can not understand the contents herein described, for this manual has been prepared
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for experienced service personnel.
WARNINGS, CAUTIONS AND NOTES

All these symbols have their specific purposes, respectively.
WARNING:
• This symbol means that there is the possibility of personal injury of the operator himself or the
nearby workers if the operator fails to follow the operating procedure prescribed in this manu-
al.
CAUTION:
• This symbol means that there is the possibility of damage to the component being repaired if
the operator fails to follow the operating procedure prescribed in this manual.
NOTE:
• To accomplish the operation in an efficient manner, additional instructions concerning the op-
eration are given in this section.
The following list describes general WARNINGS:

• Always wear safety glasses for eye protection.
• Use safety stands whenever a procedure requires you to be under the vehicle.
• Be sure that the ignition switch is always in the OFF position, unless otherwise required by
the procedure.
• Set the parking brake when working on the vehicle.
• Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide.
• Keep yourself and your clothing away from moving parts, when the engine is running, espe-
cially from the fan and belts.
• To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tail pipe, catalytic converter and muffler.
• Do not smoke while working on a vehicle.
• To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing be-
fore beginning to work on a vehicle.
• Keep hands and other objects clear of the radiator fan blades! The electric cooling fan is
mounted on the radiator and can start to operate at anytime by a rise in coolant temperature
GI–3
or turning ON of the air conditioner switch in the case of vehicles equipped with an air condi-
tioner. The electric cooling fan is also mounted on the condenser for air conditioner and starts
to operate anytime when the air conditioner switch is turned “ON”. For this reason care should
be taken to ensure that the electric cooling fan motor is completely disconnected when work-
ing under the hood.
The UNITS used in this manual are showed as the SI UNIT (International System of Unit).
“Example”
24.5 - 34.3 N·m
sGI00002-00000
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GI–4
HOW TO USE THIS MANUAL
CONTENTS OF EXPLANATION
1. Schematic Diagram of Components
(1) The schematic diagram of components that appears at the beginning of each section describes the
nomenclature and installed conditions of each component. Furthermore the tightening torque is
posted in the figure.
(2) Those parts whose reuse is not permitted bear a “★” mark for an identification purpose. Be certain
to replace these parts with new ones during the assembly.
(3) During the assembly, be sure to apply grease to those parts indicated by the mark in the figure.
(Example)
29.4 - 49.0 : Tightening torque

Unit : N⋅m
29.4 - 49.0 ★ : Non-reusable parts
29.4 - 44.1
★
r t
★
B e
14.7 - 21.6
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i
★e y q Rear bearing retainer
w Oil slinger
e Gasket
r Filler plug
w t Type T oil seal
y Extension housing dust deflector
q
u Extension housing subassembly
u i Drain plug
sGI00003-00001
2. Servicing Procedure
(1) In principle, the servicing procedure is described in the following sequence given below: Removal
→ Inspection → Installation, and Disassembly → Inspection → Assembly.
(2) The explanation covers detailed servicing methods, specifications and notes.
(3) The main point of each item explains the servicing section and servicing procedure, using illustra-
tions.
(Example)
9. Confirmation of length/shape of shift fork and shift fork

shaft e w q
(1) The following three shift fork shafts differ in the over-
all length, as shown in the right figure.
NOTE:
• Be very careful not to make any wrong installation of
these shift fork shafts.
Shift fork shafts Overall lengths (mm)
q 1st & 2nd 224
w 3rd & 4th 259
e 5th & Reverse 265 sMT00092-00085
sGI00004-00002
GI–5
(4) The inspection in this manual describes only checking operation. Therefore, if you find any malfunc-
tion, replace any defective parts with new ones.
3. SST
For those operations which require the use of any SST, the SST numbers concerned are given in bold
letters.
4. Service Specifications
Service specifications are indicated in bold letters or enclosed by heavy lines. Be certain to confirm the
specifications concerned.
5. Tightening Torque
For those operations which require the control of tightening torque, the relevant tightening torque is
given in bold letters. Be certain to confirm the tightening torque concerned.
6. Definitions of Terms
Specified Value.......... A value which represents the allowable range during the inspection and adjust-
ment.
Limit ........................... A maximum or a minimum limit which the value should not exceed or fall below.
sGI00005-00000
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GI–6
ABBREVIATION CODES
The abbreviation codes that appear in this service manual stand for the following, respectively.
Abbreviation code Original word Meaning
API American Petroleum The standards set forth by the American Petroleum Institute (abbreviated as API
Institute Classification) have been employed to evaluate and classify properties of various oils.
Engine oils for gasoline engines are classified as SD, SE, SF and so on, whereas
engine oils for diesel engines are classified as CC, CD and so on.
Assy, A/Y or Ay Assembly Refers to an assembled component comprising more than two single parts or sub-
assembly parts.
A/T, AT Automatic Transmission Refers to automatic transmission
EFI Electronic Fuel Injection Refers to electronic fuel injection.
EJ-BE EJ-D EFI EJ engine equipped with EFI system
IGN Ignition Refers to ignition
ISC Idle Speed Control Refers to idle speed control
LH Left Hand Refers to left side.
LHD, L.H.D. Left-Hand Drive Left-hand drive vehicle.
MP Multipurpose Means that the following item has multi-purposes.
RH Right Hand Refers to right side.
RHD, R.H.D. Right-Hand Drive Right hand drive vehicle
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S/A Sub-Assembly Refers to a component comprising more than two single parts which are welded,
staked, or studded to each other to form a single component.
SAE Society of Automotive For example, automotive oils are designated as SAE so and so number.
Engineers These designation numbers have been set forth by the Society of Automotive
Engineers in the United States of America (SAE). The larger the SAE number, the
higher the oil viscosity. Conversely, the smaller the SAE number, the lower the oil
viscosity.
SST Special Service Tool Refers to a tool designed for a specific purpose.
STD Standard When referring to automotive parts, “standard” represents those parts which have been
installed originally by the manufacturer and which have standard dimensions.
T Torque Refers to tightening torque.
VSV Vacuum Switching Refers to vacuum switching valve.
Valve
W/ With Denotes that the following part is attached.
sGI00006-00000
The abbreviation codes that appear in the figure stand for the following, respectively.
B Bolt S Screw
N Nut W Washer
sGI00007-00000
GI–7
GENERAL SERVICE INSTRUCTION
1. Use fender covers, seat covers and floor sheets so that the vehicle may not get dirty or be scratched.
2. Jacking up
(1) When only the front section or rear section of the vehicle is jacked up, be sure to place chocks at
the wheels so as to insure safe operations.
(2) When the vehicle has been jacked up, be sure to support the vehicle at the specified section using
the safety stands. (Refer to the relevant Chassis section in the manual for the vehicle concerned.)
3. Handling instructions related to battery.

(1) Before you start performing the electrical works, make certain to disconnect the battery ground
cable terminal from the negative (–) terminal of the battery.
NOTE:
• Before disconnecting the battery ground cable terminal from the negative (–) terminal of the battery,
be sure to read out the diagnosis code of the EFI systems if it equipped.
• After reconnect the battery ground cable terminal to the negative terminal of the battery, be sure to
reset the watch or radio, if vehicle equipped with such equipments.
(2) When it becomes necessary to disconnect the battery power supply for the purpose of carrying out
checks or repairs, always disconnect the negative (–) terminal of the battery ground cable from neg-
ative terminal of the battery first.
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(3) To avoid damaging battery plates, after the terminal nut has been loosened, pull out the battery
ground cable terminal straight upward, rather than turning or prying the terminal.
NOTE:
• Be sure to employ the battery terminal puller (commercially available) to remove battery ground cable
terminal from the negative terminal of the battery, if encountered any difficulty.
(4) Clean the battery terminal posts or battery ground terminals, using a cloth. Never use a file or other
adhesive agents.
(5) When connecting the battery ground cable terminal to the battery, first the battery ground cable ter-
minal should be fitted onto the battery post with the attaching nut in a loose state.
Then, tighten the nut. Never tap the terminal onto the battery post, using the hammer or spanner
wrench or the like.
(6) As for the cover at the positive (+) terminal side, be sure to install it at the correct position.
4. For increased work efficiency and improved accuracy, be sure to utilize the SSTs (Special Service Tools)
effectively.
sGI00008-00000
TO INDEX TO NEXT SECTION

TO INDEX
MT
MANUAL TRANSMISSION
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OUTLINE ................................................... MT– 2 COUNTERSHAFT ................................ MT–18

SECTIONAL VIEW ............................... MT– 2 INSPECTION PRIOR TO
TRANSMISSION ASSEMBLY .................. MT– 3 OPERATION .................................... MT–18
COMPONENTS (1) .............................. MT– 3 DISASSEMBLY .................................... MT–18
COMPONENTS (2) .............................. MT– 4 INSPECTION ....................................... MT–19
COMPONENTS (3) .............................. MT– 5 REPLACEMENT OF CONICAL
COMPONENTS (4) .............................. MT– 6 SPRING WASHER ........................... MT–20
DISASSEMBLY .................................... MT– 7 INSPECTION ....................................... MT–20
INSPECTION ....................................... MT– 9 ASSEMBLY .......................................... MT–21
SHIFT FORKS AND HEADS ................ MT–10 OUTPUT SHAFT .................................. MT–24
REPLACEMENT OF TYPE S DISASSEMBLY .................................... MT–24
OIL SEAL ......................................... MT–10 INSPECTION ....................................... MT–25
BIMETAL FORMED BUSH ................... MT–11 ASSEMBLY .......................................... MT–25
SHIFT LEVER & SHIFT RELATED INSTALLATION ................................... MT–26
PARTS REPLACEMENT .................. MT–11 APPENDIX ................................................. MT–31
INSPECTION PRIOR TO SSTs (Special Service Tools) .............. MT–31
OPERATION .................................... MT–12 SERVICE SPECIFICATIONS ................ MT–32
DISASSEMBLY .................................... MT–12 AT THE INPUT SHAFT SIDE ................ MT–32
INSPECTION ....................................... MT–13 AT THE COUNTER SHAFT SIDE ......... MT–33
ASSEMBLY .......................................... MT–15 TIGHTENING TORQUE ....................... MT–33
sMT00001-00000
MT–2
OUTLINE
SECTIONAL VIEW
Clutch housing
Input shaft
Reverse idler gear

Reverse idler gear shaft
5th gear
1st gear Speedometer drive gear
3rd gear
Output shaft
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Extension housing
Counter gear shaft

2nd gear
Reverse gear Transmission case
Sub gears
sMT00002-00001
MT–3
TRANSMISSION ASSEMBLY
COMPONENTS (1)
: Tightening torque
Unit : N·m
★ : Non-reusable parts
18.6 - 30.4 6.9 - 9.8 @6

!1 ★
!2 @8
★
B @7
14.7 - 21.6 @9
★
o !8
u i !9
y 18.6 - 30.4 ★
!8
!0★ !7
B
★
@2 !8★
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B
!3 !6
!4 ★ B
6.9 - 9.8 !5 18.6 - 30.4 !8
B @1 14.7 - 21.6
#0
!3 ★ !8★
49.0 - 68.6
14.7 - 21.6 !8★
!4 @5
B !5 @4
B
q t B 18.6 - 30.4
!3★
@0 !4
r !5
e @3
w★
B
49.0 - 68.6
q Clutch housing !6 5th & reverse shift fork shaft

w Type S oil seal !7 5th & reverse shift head
e Shift interlock plate !8 Slotted spring pin
r Tension spring !9 5th shift fork
t Reverse shift arm @0 3rd & 4th shift fork shaft
y Input shaft bearing lock plate @1 3rd & 4th shift head
u Reverse idler gear @2 3rd & 4th shift fork
i Reverse idler gear thrust washer @3 1st & 2nd shift fork shaft
o Reverse idler gear shaft @4 1st & 2nd shift fork
!0 Slotted spring pin @5 1st & 2nd shift head
!1 Hexagon socket bolt @6 Oil receiver pipe
!2 Gasket @7 Tight plug
!3 Gasket @8 Transmission case
!4 Compression spring @9 Transmission magnet
!5 Ball #0 Breather
sMT00003-00002
MT–4
COMPONENTS (2)
: Tightening torque
Unit : N·m
6.9 - 9.8
B
#2 29.4 - 49.0
29.4 - 49.0
★ 29.4 - 44.1 ★
#3 @9
#4 ★ @8
6.9 - 9.8 B @7
14.7 - 21.6
#9
B
B
★ ★ $0 #0
#5 @7
r
#6 @6
29.4 - 49.0 @5
!1 ★ #1
!2 177.0 - 216.0 @4★
!4 !3
★ @3
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★ ★
t #8 @2
14.7 - 21.6 B - 21.6
14.7 ★ @1
B @0
W
18.6 - 30.4 y
★
q w u
B
e
i
★ !7
#7
o !8★
!5
!0 !6
!9
q Torsion spring @1 Shaft snap ring

w Reverse restrict cam @2 Lock nut
e Reverse restrict shaft @3 Speedometer drive gear
r Select lever subassembly @4 Radial ball bearing
t Grooved pin @5 Rear bearing retainer
y Control shaft cover @6 Oil slinger
u Transmission case cover gasket @7 Gasket
i Torsion spring @8 Filler plug
o Select inner lever @9 Type T oil seal
!0 Output shaft #0 Extension housing dust deflector
!1 Reverse restrict pin holder #1 Extension housing subassembly
!2 Gasket #2 Speedometer sleeve lock plate
!3 Compression spring #3 Type V oil seal
!4 Ball #4 Speedometer sleeve assembly
!5 Transmission case #5 O-ring
!6 Shift inner lever #6 Speedometer driven gear subassembly
!7 Control shaft boot #7 Type T oil seal
!8 Grooved pin #8 Type K oil seal
!9 Shift lever shaft subassembly #9 Oil guide plate
@0 Radial ball bearing $0 Drain plug
sMT00004-00003
MT–5
COMPONENTS (3)
✩ : Selection parts
!3
★ ★
✩ ★ ✩ !2
q w !1
!0
u
o
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u
y
t
@1
r
@0
★
✩i ★ !9
✩
!8
!7 !5
!5
!4
✩ !6
q Shaft snap ring !2 Needle roller bearing

w Radial ball bearing (front) !3 3rd gear
e Input shaft !4 Synchronizer ring No. 1
r Needle roller bearing !5 Synchromesh shifting key spring
t 5th gear !6 Synchronizer No. 2 hub assembly
y Synchronizer ring No. 1 !7 Synchromesh shifting key
u Synchronizer shifting key spring !8 Shaft snap ring
i Synchronizer No. 3 hub assembly !9 Wave spring
o Synchronizer shifting key @0 Synchronizer ring No. 1
!0 Transmission hub sleeve stopper @1 Split type needle roller bearing
!1 Shaft snap ring
sMT00005-00004
MT–6
COMPONENTS (4)
✩ : Selection parts
!3
!0
!2
★ !0
✩
@1 ★
o @0
i
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u
y ✩ !1 !9
t
★
r ★
★ e !8
w !7
★✩ q
!6
!5
!4
q Shaft snap bearing !1 Synchronizer No. 1 hub assembly

w Radial ball bearing !2 Synchromesh shifting key
e 1st gear thrust washer !3 Synchronizer ring No. 3
r Shaft snap ring !4 Split type needle roller bearing
t 1st sub-gear !5 2nd gear
y Conical spring washer !6 Conical spring washer
u Needle roller bearing !7 2nd sub-gear
i 1st gear !8 Shaft snap ring
o Synchronizer ring No. 2 !9 Counter gear
!0 Synchromesh shifting key spring @0 Radial ball bearing
@1 Shaft snap ring
sMT00006-00005
MT–7
DISASSEMBLY
Disassembly of shift and select lever related parts
NOTE: (A)
• After the sifting feeling and continuity for the reverse
backup lamp switch have been checked.
1. Remove the clutch-related parts.

(Detach the engagement of the spring (A).)
2. Stand the transmission case assembly in such a way that
it faces toward the clutch housing lower side.
sMT00007-00006
3. Remove the control shaft cover with gasket {Bolts (C) are
(C)
used for the reamer bolts}.
4. Remove the compression spring and ball of the reverse
restrict pin holder (B) with the gasket.
NOTE:
• Disassemble the control shaft cover, as required.
• Prior to the disassembly, drive out the grooved pin of
the shift lever shaft.
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sMT00008-00007
5. Remove the hexagon bolt (A) of the reverse idler gear

shaft with the gasket.
Groove pin Shift inner lever
NOTE:
• This hexagon bolt (A) is for securing the reverse idle
shaft. Hence, be sure to remove this bolt before the
transmission is disassembled.
6. Pull out the shift lever subassembly and shift inner lever by
driving out the grooved pin (E). Driving-off direction
NOTE:
• As for the grooved pin of the shift inner lever, make sMT00009-00008
sure to drive off the pin, working from the underside,

after the transmission case has been taken out. (The
bottom of the grooved pin hole of the shift inner lever is
step-formed. Hence, the pin can not be driven off from
the top side.)
7. Remove the reverse restrict cam (A), torsion spring (B)

and reverse restrict shaft (C) by removing the hexagon
bolt (D) with the gasket.
NOTE:
(B)
• The reverse restrict cam (A) has the correct assem- (A)
bling direction to be observed during assembly.
(C)
Therefore, when disassembling the reverse restrict
cam (A), make sure to remember the assembling direc- (D)
tion in order that the part may be assembled correctly.
(E)
8. Remove the backup lamp switch assembly with the gas-
ket.
NOTE:
• Never reuse the removed gasket. sMT00010-00009
MT–8
Removal of extension housing
NOTE: SIDE VIEW
• Remove the extension housing and output shaft only
after checks have been made for oil leakage at the rear
side, or deformation, etc. of the dust reflector (A). (B)
(A)
1. Remove the speedometer shaft sleeve subassembly (B).
2. Remove the eight bolts of the extension housing together
with the engine rear mounting bracket.
3. Tap the rib section of the extension housing. Then, pull out
it toward you. sMT00011-00010
Disassembly of transmission case

NOTE:
• Disassemble the transmission case after checking to
see if any variation in rotation exists between the input
and output shafts. (B)
1. Pull out the oil slinger from the countershaft.

(C) (A)
2. Pull out the transmission magnet (A). Check the amount of
dust that has collected on the magnet.
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sMT00012-00011
3. Remove the bearing retainer.

4. Detach the shaft snap ring (B) of the output shaft radial
ball bearing (for rear).
5. Remove the 10 bolts of the transmission case, (including
the two bolts to be removed from the lower side of the (A)
clutch housing).
6. Tap the rib section (C) of the transmission case. Then, pull
it out toward you.
NOTE:
• This pulling operation can be carried out also by means
of the SST (09306-87602-000). sMT00013-00012
Removal of shift fork

NOTE:
• Check the movement of reverse shift arm and contact
width between the shift fork and the rib sleeve.
• Make sure that the shift fork is removed only after the
gear concerned is placed in neutral.
sMT00014-00000
1. Detach the tension spring (A).

2. Remove the compression springs and balls by removing
the three hexagon bolts with the gaskets (B).
(C)
3. Remove the 5th & reverse shift fork shaft by removing the
slotted spring pin of the shift fork and shift head. (D)
NOTE:
• When the slotted spring pin is driven out, a measure to
(A)
sustain the reaction force for pulling out should be
taken at the opposite side.
4. Pull out reverse idler gear shaft (C), thrust washer (resin (B)
made) and reverse idler gear (D). sMT00015-00013
MT–9
5. Remove the 1st & 2nd shift fork shaft and the 3rd & 4th
shift fork shaft progressively, following the procedure de-
scribed in the steps 3 above.
sMT00016-00014
Removal of input shaft and counter shaft

NOTE: Interlock plates
• Confirm that each gear can be engaged properly.
1. Pull out the output shaft assembly with the needle roller
bearing and synchronizer ring and wave spring.
2. Remove the reverse shift arm with the shift interlock plates
by removing the three bolts.
3. Remove the input shaft bearing lock plate by removing the
three bolts.
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4. While holding both the input shaft and countershaft as- sMT00017-00015
sembly by your hands, pull out them in such a way that

they face toward the upper side.
INSPECTION
1. Measure the free length of the compression springs for
shift fork shafts and reverse restrict pin.
For shift fork shafts For reverse restrict pin
L
Free length L (mm) 40 24
Long as installed (N) 47.33 28.83
Height as installed (mm) 30 17
2. Visually inspect the balls for deformation or scratches.

sMT00018-00016
3. Measure the contact width section between the select

inner lever shaft and shift heads.
A (Select inner lever) B (Shaft inner lever heads)
–0.02
Specified value (mm) 15 –0.12 15 +0.2
+0.1
B
sMT00019-00017
MT–10
SHIFT FORKS AND HEADS B B
Inspection B
1. Measure the outer diameter of the shift fork shafts and
inner diameter of the case sides.
A (Case sides) B (Shaft sides)
Specified value (mm) 13.0 +0.043
+0 13.0 –0.05
–0.08
A
B B B
sMT00020-00018
2. Measure the contact width section between the shift

heads and the shift inner lever.
A (Shift heads) B (Shift inner lever)
+0.1
Specified value (mm) 12.1 +0 12 –0.02
–0.12
B
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sMT00021-00019
Reverse idler gear

1. Visually inspect the chamfered section of the reverse idler
gear for damage.
2. Measure the bore diameter of the reverse idler gear bush. D
3. Measure the outer diameter of the reverse idler gear shaft.
Also, check its surface for scores, etc. d
d (Reverse idler gear) D (Shaft)

+0.061
Specified value (mm) 20 +0.032 20.0 +0
–0.013
sMT00022-00020
REPLACEMENT OF TYPE S OIL SEAL

1. Remove the Type S oil seal, with a screw driver.
2. Apply lithium based MP grease to the lip section of the
new oil seal.
3. Install the new oil seal, using a box wrench (outer diame-
ter 35 mm) or the like with a hammer.
NOTE:
• Never reuse the removed oil seal.
sMT00023-00021
MT–11
BIMETAL FORMED BUSH
1. Removed the oil seal.
(Recommended SST: 09308-00010-000)
2. Visually inspect the inner surface of the bimetal formed
bush for discoloration or scratch.
3. Measure the inner diameter of the bimetal formed bush.
Specified Value: 036.0 - 36.025 mm
CAUTION:
• The bore diameter of the bimetal formed bush has
been machined, if the part exceeds the allowable limit, sMT00024-00022
it would cause oil leakage. Therefore, be certain to re-

place the bimetal formed bush as the extension hous-
ing subassembly.
4. Apply lithium based MP grease to the lip section of the

new oil seal.
5. Install the new oil seal.
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SHIFT LEVER & SHIFT RELATED PARTS

REPLACEMENT
Removal
1. Remove the select lever boot.
2. Remove the tight plug (if necessary).
3. Remove the Type T oil seal.
NOTE:
• Never reuse the removed tight plug and oil seal.
sMT00025-00023
Installation
1. Install the new tight plug.
2. Install the new Type T oil seal. (A)
3. Ensure that the protrusion section (A) of the Type T oil seal
conforms to the specified value.
Specified Value: 5 ± 0.3 mm
CAUTION:
• If the protrusion section (A) exceeds the specification
above (i.e. above 5.3 mm), it would cause oil leakage.
sMT00026-00024
4. Check that continuity exists at the backup lamp switch as-

sembly.
MT–12
INSPECTION PRIOR TO OPERATION
1. Measure the contact section of the shift forks for 3rd gear
(A), 5th gear (B) and with the hub sleeves.
Unit: mm
3rd gear (A) and 5th gear (B)
Fork Hub sleeve
–0.1 +0.12
Specified Value 7 –0.3 7 +0.05
Allowable Limit 6.6 7.2
sMT00027-00025
2. Measure and record the thrust clearance for 3rd gear (C)
and 5th gear (D), using a feeler gauge.
Unit: mm
(C) (D)
Specified Value 0.10 - 0.52 0.10 - 0.40
NOTE:
• Ensure that the thrust clearance is measured at several
points.
• If the measured thrust clearance fails to conform to the
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specification above, proceed to disassemble the input sMT00028-00026
shaft assembly.
DISASSEMBLY
1. Using soft jaws, clamp the input shaft assembly in a vice
so as to avoid the damage in the spline section.
2. Remove the selection type shaft snap ring at the rear side.
3. For reference at the time of installation, measure and
record the thickness of the removed shaft snap ring.
sMT00029-00027
4. Remove the following parts, using the following SST.

SST: 09950-20017-000
NOTE:
• The following parts can be removed by driving out the
input shaft by means of a press, with the 3rd gear sec- SST
tion sustained by the SST (09334-87301-000).
(1) Synchronizer No. 2 hub assembly

(2) Synchronizer ring No. 1
(3) 3rd gear sMT00030-00028
5. Remove the needle roller bearing.

6. Remove the selection type shaft snap ring.
record the thickness of the removed shaft snap ring.
8. Remove the transmission hub sleeve stopper.
sMT00031-00029
MT–13
9. Remove the following parts, using the following SST.
SST: 09950-20017-000
NOTE:
• The following parts can be removed by driving out the
input shaft by means of a press, with the 5th gear sec- SST
tion sustained by the SST (09334-87301-000).

(3) 5th gear sMT00032-00030
10. Remove the split type needle roller bearing. (B)

CAUTION:
• When you remove the split type needle roller bearing,
make sure that the gap (B) at the opening of the needle
roller bearing will not exceed the outer diameter of the
input shaft by more than 5 mm.
ProCarManuals.com
sMT00033-00031

12. Measure and record the thickness of the removed snap
ring for the reference of installation.
13. Remove the radial ball bearing at the front side, using the
following SST.
SST: 09950-20017-000
sMT00034-00032
INSPECTION
1. Check the clearance between the gear tapered section
and the synchronizer rings.
Specified Value: 0.95 - 1.35 mm
NOTE:
• The measurement should be conducted at several
places on the circumference.
sMT00035-00033
2. Measure the outer diameter of the input shaft at the sec-

tions (A), (B) and (C) as shown in the right figure.
B C
3. Visually inspect the sections (A), (B) and (C) for scratch or A
discoloration.
Specified value (mm)
A and B 32 –0.009
–0.029
C 20 –0.016
–0.034
sMT00036-00034
MT–14
4. Measure the dimensions between the outer diameter of
the synchronizer hub No. 2 for 3rd and synchronizer hub
No. 3 for 5th (A) and bore diameter of both sleeves (B).
B
Outer dia. of hub Bore dia. of hub sleeve
Classification Identification A
A (mm) B (mm)
No. 2 57.78 - 57.84 57.87 - 57.97 Yellow
No. 1 57.68 - 57.74 57.77 - 57.87 None
A
No. 3 57.58 - 57.64 57.67 - 57.77 White
CAUTION: sMT00037-00035
• If any part which has exceeded the value specified in
the table above should be used, it would cause abnor- A B
mal noise. Therefore, be certain to replace those parts
as a set.
5. Measure the thickness of the synchronizer hub No. 2 (C)

and No. 3 (D).
A B
Specified value (mm) 18.55 ± 0.03 12.4 ± 0.03
ProCarManuals.com
sMT00038-00036
6. Measure the height of the transmission hub sleeve stop-

per.
A section:
Specified Value: 7.2 +0.05
–0.01 mm
sMT00039-00037
7. Measure the thickness (L) and inner diameter (D) of the

3rd and 5th gears.
Inner diameter D
3rd gear 5th gear
D D
+0.025
Specified value (mm) 37.0 +0
Thickness L
3rd gear 5th gear L L
Specified value (mm) 37.95 ± 0.03 27.85 ± 0.03 3rd gear 5th gear
sMT00040-00038
8. Measure the height of the synchromesh shifting key.

Specified Value: 5 –0.2
–0.4 mm
NOTE:
• All of the six shifting keys assembled in the input shaft
are common parts.
9. Visually inspect the synchromesh shifting key spring for

wear or damage.
sMT00041-00039
MT–15
ASSEMBLY
(B)
NOTE:
• Be sure to apply gear oil to the relevant parts at every
process.
• Never reuse those parts bearing an “★” mark posted at
the page MT–12.
1. Install the split type needle roller bearing and apply gear
oil to it.
CAUTION: sMT00042-00040
• During the split type needle roller bearing installation,

make sure that the gap (B) at the opening of the needle
roller bearing does not exceed the outer diameter of
the input shaft by more than 5 mm.
2. Install the 5th gear and synchronizer ring to the input

ProCarManuals.com
shaft.
3. Assemble the synchromesh shifting key and key spring to
the hub as shown in the illustration.
NOTE:
• Make sure that no opening end of the shifting key
spring comes in the same direction in assembly.
• Be sure to align the missing teeth provided at three
points when the hub and sleeve are assembled.
• The same hub sleeve is used for both the 3rd gear and
4th gear. However, the hub differs in shape between
the 3rd gear and the 4th gear.
sMT00043-00041
4. Ensure that the grooved section in the protrusion position

of the synchronizer No. 3 hub faces toward the front (i.e.
the 5th gear) side and press them.
NOTE:
• Make sure that the synchronizer rings are aligned with
the shifting key grooves (three points), while the syn-
chronizer No. 3 hub is being pressed.
sMT00044-00042
5. Install the transmission hub sleeve stopper.

NOTE:
• Ensure that the oil groove section of the 5th shifting
key retainer faces toward the 3rd gear side.
sMT00045-00043
MT–16
6. Selection procedure for new shaft snap ring
(1) Using the table below, select a new shaft snap ring
having the same thickness as that measured at the
time of the removal, or the thinnest shaft snap ring.
Then, install the thus-selected snap ring on the shaft
snap ring installation groove of the input shaft.
(2) Measure the end play, using a feeler gauge as shown
in the right figure.
(3) Select a snap ring shaft whose end play is zero or al-
most zero and that can be set readily, using the table
below. sMT00046-00044
(4) Again, ensure that the end play between the 5th shifting key retainer and the shaft snap ring con-
forms to the specified value.
End Play:
Specified Value: 0
Allowable Limit: Less than 0.16 mm
Part No. Thickness Identification Part No. Thickness Identification
90045-20263 2.06 None 90045-20267 1.90 Brown
90045-20264 2.02 Brown 90045-20268 1.86 Blue
ProCarManuals.com
90045-22265 1.98 Blue 90045-20269 1.82 None

90045-20266 1.94 None 90045-20270 2.10 Brown
NOTE:
• The shaft snap rings in the table above are the common parts as those used when the hub of the
countershaft is set.
• As for the parts number, confirm it by the parts catalogue.
sMT00047-00000
7. Install the needle roller bearing and apply gear oil.

8. Install the 3rd gear and synchronizer ring.
9. Assemble the synchromesh shifting key spring and shift-
ing key to the synchronizer No. 2 hub assembly.
NOTE:
• For the handling of the hub sleeve, refer to the step 3
at page MT–22.
(A)
sMT00048-00045
10. Ensure that the oil grooved section (A) of the synchronizer
No. 2 hub assembly faces toward the 3rd gear side.
NOTE:
• Make sure that the synchronizer rings are aligned with
the shifting key grooves (three points), while the syn-
chronizer hub No. 3 is being pressed.
sMT00049-00000
MT–17
11. Selection procedure for new shaft snap ring
(1) For the selection procedure of the shaft snap ring,
refer to the step 6 at page MT–23.
sMT00050-00046
(2) Again, ensure that the end play between the hub and the shaft snap ring conforms to the specified
value.
End Play:
Specified Value: 0
90045-20271 2.06 None 90045-20275 1.90 Brown
90045-20272 2.02 Brown 90045-20276 1.86 Blue
90045-22273 1.98 Blue 90045-20277 1.82 None
ProCarManuals.com
90045-20274 1.94 None 90045-20278 2.10 Brown
NOTE:
• The shaft snap rings in the table above are the common parts as those used at the front bearing sec-
tion of the input shaft.
• As for the parts number, confirm it by the parts catalogue.
sMT00051-00000
12. Install the new radial ball bearing by using a press.

NOTE:
• Make sure that the radial ball bearing having a seal
faces toward the front.
• Be very careful not to drop and disassemble the syn-
chronizer ring and hub sleeve, while the radial ball
bearing is being pressed.
Seal
• The assembling operation of the radial ball bearing
may be conducted first.
13. In the same manner of the step 11 above, install the selec- sMT00052-00047
tion type shaft snap ring.

MT–18
COUNTERSHAFT
INSPECTION PRIOR TO OPERATION
1. Measure the contact width section of the synchronizer
No.1 hub assembly (B) and the 1st & 2nd shift fork (A).
A (Thickness of fork) B (Width of hub)
–0.1
(A)
Specified value (mm) 10 –0.3 10 +0.12
+0.05
Allowable limit (mm) 9.6 10.2
2. Measure and record the thrust clearance for 1st gear (C)
and 2nd gear (D) as shown in the right figure.
NOTE: (B)
• Prior to disassembling, make sure to measure the
thrust clearance at several points.
• If the measured thrust clearance exceeds the specified
value in the table below, proceed to disassemble the
countershaft.
C (Clearance of 1st gear) D (Clearance of 2nd gear)
Specified value (mm) 0.10 - 0.56 0.10 - 0.44 (D) (C)
ProCarManuals.com
sMT00053-00048
DISASSEMBLY
1. Using soft jaws, clamp the spline section of the counter-
shaft assembly in a vice so as to avoid damage.
record the thickness of the removed selection type shaft
snap ring.
NOTE:
• Never reuse the removed shaft snap ring.
sMT00054-00049
4. Remove the following parts by pressing the countershaft

by means of a suitable rod.
(1) Radial ball bearing
(2) 1st gear thrust washer
(3) 1st gear
(5) Needle roller bearing
NOTE:
• The parts described above can be removed by press-
ing the countershaft, while the 1st gear is supported by
means of the anvil (09334-87301-000). sMT00055-00050

NOTE:

record the removed selection type shaft snap ring.
sMT00056-00051
MT–19
7. Remove the following parts.
(3) 2nd gear with sub-gear
NOTE:
• The parts described above can be removed by press-
ing the countershaft, while the 2nd gear (sub-gear sur-
face) is supported by means of the anvil (09334-87301-
000).
sMT00057-00052
8. Remove the split type needle roller bearing.

CAUTION:
• When removing the split type needle roller bearing,
make sure that the gap (A) at the opening of the needle
roller bearing does not exceed the outer diameter of
the countershaft by more than 5 mm. Failure to ob- (A)
serve this caution would cause abnormal noise from
the transmission.
ProCarManuals.com
sMT00058-00053
INSPECTION
1. Measure the height of the synchromesh shifting spring
keys.
Specified Value: 5.1 ± 0.1 mm
2. Visually inspect the spring for synchromesh shifting key

spring for damage or distortion.
sMT00059-00054
3. Measure the outer diameter of the countershaft at the sec-

tions (A) and (B).
A B
A B
–0.009
Specified value (mm) 32 –0.029
4. Visually inspect the sections (A) and (B) for discoloration

and scratches.
sMT00060-00055
5. Measure the thickness of the 1st gear thrust washer.

sMT00061-00056
MT–20
6. Measure the dimensions between the outer diameter of
the synchronizer No. 1 hub (A) and the bore diameter of
synchronizer hub sleeve (B).
[Reference information]
The synchronizer No. 1 hub and the synchronizer hub (B)
sleeve are available only as a set. An identification mark is
applied to the end surface of the synchronizer hub.
(A)
Classification (A) (mm) (B) (mm) Identification
No. 2 69.78 - 69.84 69.87 - 69.97 Yellow
No. 1 69.68 - 69.74 69.77 - 69.87 None sMT00062-00057
No. 3 69.58 - 69.64 69.67 - 69.77 White
CAUTION: (A)
• When replacing those parts (A) and (B), be sure to re-
place them as a set.
7. Measure the thickness (A) of the synchronizer No. 1 hub.

ProCarManuals.com
sMT00063-00058
8. Measure the inner diameter of 1st and 2nd gear.

A (1st gear) B (2nd gear)
+0.025
Specified value (mm) 37.0 +0
9. Measure the thickness of 1st and 2nd gear. A B
C (1st gear) D (2nd gear)

Specified value (mm) 27.27 - 27.37 36.23 - 36.33
C D
sMT00064-00059
REPLACEMENT OF CONICAL SPRING WASHER

1. Clamp the 1st gear together with the square bracket in a
vice as shown in the right figure.
2. Remove the conical spring washer and sub-gear by re-
moving the shaft snap ring.
NOTE:
sMT00065-00060
INSPECTION
1. Measure the height of the conical spring washer. Front
Specified Value: 2.01 mm
Allowable Limit: 1.04 mm
(1)
2. Place the conical spring washer (1) and sub-gear on the
1st gear.
3. Ensure that the expanded side of the conical spring wash-
er faces toward the sub-gear side as shown in the right
figure.
sMT00066-00061
MT–21
4. Install the new shaft snap ring by pressing the conical
spring washer, using the following SST.
NOTE:
SST: 09351-32070-000
(component of 09350-32014-000)
sMT00067-00062
5. In the same manner of the operation stated above, re-

place the conical spring washer for the 2nd sub-gear.
6. Ensure that the expanded side of the conical spring wash-
er for gear No. 2 (1) faces toward the sub-gear side as
shown in the right figure.
7. Install the new shaft snap ring by pressing the conical
spring washer, using the above SST. (1)
NOTE:
Rear
ProCarManuals.com
sMT00068-00063
ASSEMBLY
NOTE:
• When assembling the countershaft, apply gear oil at
each step and assemble each part.
• As for those parts which bear the “★” marks at page (A)
MT–13, never reuse them.
1. Install the split type needle roller bearing.

CAUTION:
• When installing the split type needle roller bearing, sMT00069-00064
make sure that the gap (A) at the opening of the needle
roller bearing will not exceed the outer diameter of the
countershaft by more than 5 mm.
2. Apply gear oil to the outer periphery of the split type nee-
dle roller bearing and install the 2nd gear to the counter-
shaft.
3. Place the synchronizer ring No. 3 into the synchronizer

No. 1 hub.
(A) (B)
NOTE:
• The external appearance of the synchronizer ring No. 3
{for 2nd gear (B)} differs from that of the synchronizer
ring No. 2 {for 1st gear (A)}, as evident from the right il-
lustration.
sMT00070-00065
MT–22
4. Install the synchronizer ring No. 3 to the synchronizer
No. 1.
5. Assemble the synchromesh shifting key and synchromesh
shifting key spring to the synchronizer No. 1 hub assem-
bly.
NOTE:
• During assembling, make sure that the mating ends of
the shifting key springs come at different positions.
(A)
• When installing the hub and hub sleeve, be sure to
align three teeth-missing sections.
sMT00071-00066
6. Prior to pressing the synchronizer No. 1 hub assembly,

make sure that the protrusion section (A) of the hub faces
toward the front side. (The hub sleeve has a shift fork
groove.)
ProCarManuals.com
7. Apply gear oil to the tapered section of the 2nd gear.

8. Apply gear oil to the spline section.
9. Align the spline section. Press the synchronizer No. 2 hub
assembly.
NOTE:
• While the synchronizer No. 2 hub assembly is being
pressed into the countershaft, make sure that the shift-
ing key assembled to the hub is aligned with the shift
key groove of the synchronizer ring.
sMT00072-00067
10. Selection sequence of new shaft snap ring.

(1) Using the table below, select a new shaft snap ring
having the same thickness as that measured at the
time of removal, or the thinnest shaft snap ring.
Then, install the thus-selected shaft snap ring on the
shaft snap ring installation groove of the countershaft.
(2) Measure the end play, using a feeler gauge as shown
(3) Select a snap ring shaft whose end play is zero or al-
most zero and that can be set readily, using the table
at page MT–30. Then, proceed to install it. sMT00073-00068
MT–23
(4) Again, ensure that the end play conforms to the specified value.
End Play:
Specified Value: 0
90045-20263 2.06 None 90045-20267 1.90 Brown
90045-20264 2.02 Brown 90045-20268 1.86 Blue
90045-22265 1.98 Blue 90045-20269 1.82 None
90045-20266 1.94 None 90045-20270 2.10 Brown
NOTE:
• The shaft snap rings in the table above are the same as those used when the hub of the input shaft
is set.
• As for the parts number,confirm it by the parts catalogue.
sMT00074-00000
ProCarManuals.com
11. Install the needle roller bearing. Apply gear oil to the outer
periphery of the needle roller bearing.
12. Place the synchronizer ring No. 2 (the ring having missing
teeth).
13. Install the 1st gear with the sub-gear assembled.
14. Install the 1st gear thrust washer. (A)
NOTE:
• Ensure that the protrusion section (A) of the 1st gear
thrust washer faces toward the front side.
sMT00075-00069
15. Press the new radial ball bearing. (This bearing has no
seal.)
sMT00076-00070
16. Selection sequence of new shaft snap ring

(1) For the selection procedure of the shaft snap ring,
refer to the step 10 above.
sMT00077-00071
MT–24
(2) Ensure that the end play conforms to the specified value.
End Play:
Specified Value: 0
90045-20279 2.06 None 90045-20283 1.90 Brown
90045-20280 2.02 Brown 90045-20284 1.86 Blue
90045-22281 1.98 Blue 90045-20285 1.82 None
90045-20282 1.94 None 90045-20286 2.10 Brown
NOTE:
• As for the parts number,confirm it by the parts catalogue.
sMT00078-00000
ProCarManuals.com
OUTPUT SHAFT
DISASSEMBLY
1. Remove the radial ball bearing (for rear), using the follow-
ing SST.
SST: 09306-87602-000
NOTE:
• Never reuse the removed bearing. SST
2. Pull out the speedometer drive gear.

sMT00079-00072
3. Using soft jaws, clamp the spline section of the output

shaft in a vice so as to avoid damage.
4. Remove the lock section of the lock nut and remove the
lock nut, using a 32 mm ring wrench.
NOTE:
• Do not reuse the removed lock nut.
sMT00080-00073
5. Remove the radial ball bearing (for center), using the fol-
lowing SST.
SST: 09306-87602-000
NOTE:
• Never reuse the removed bearing.
SST
sMT00081-00074
MT–25
INSPECTION
1. Check the clearance between the synchronizer ring and
gear tapered section.
Specified value (mm) 0.95 - 1.35
2. Visually inspect the gear and spline section of the output

shaft for wear and damage.
sMT00082-00075
ASSEMBLY
1. Press the inner race of the new radial ball bearing.
NOTE:
• Ensure that the retaining section (Namely, the side hav-
ing the seal.) of the radial ball bearing faces toward the
rear side.
• The radial ball bearing can be pressed by using either
the SST (09310-87302-000) or a pipe with which can
press the inner race.
ProCarManuals.com
sMT00083-00076
2. Insert a 32 mm torque header into the output shaft.

3. Using soft jaws, clamp the spline section of the output
shaft in a vice so as to avoid damage.
4. Tighten the new lock nut with the torque wrench.
Tightening Torque: 177.0 - 216.0 N·m
sMT00084-00077
5. Stake the new lock nut.

NOTE:
• When staking the new lock nut, point a suitable staking
tool toward the output shaft axis center to lock securely,
as shown in the right upper figure.
• Poor staking, such as shown in the right middle and
lower figures, may cause loosening of the lock nut.
sMT00085-00078
MT–26
6. Install the speedometer drive gear.
7. Press the inner race of the new radial ball bearing (for rear
use), using the following steel pipe dimension.
CAUTION:
• Since the speedometer drive gear is made of nylon, it (A)
may be deformed if the radial ball bearing (for rear use)
is pressed more deeply than the specified depth
(93.00 mm).
• Therefore, be sure to press the new radial ball bearing
(for rear use) carefully. When the radial ball bearing
comes in contact with the speedometer gear, stop sMT00086-00079
pressing. At this time, ensure that the depth is

93.00 mm.
• For this operation, it is advisable to use the following
press-fitting tool (A) with the dimensions given below.
Specified value (mm)
Overall depth 93.00
Outer diameter 35.00
Inner diameter 25.00
ProCarManuals.com
INSTALLATION
1. For easier installation of the shaft assemblies to the trans-
mission case, align the teeth of the 1st and 2nd sub-gears
with those of the gears of the input shaft. The number of
the teeth of each sub-gear is one less than that of the
main gear.
NOTE:
• Before installing the countershaft and input shaft as-
sembly to the transmission case, make sure that each
gear is in its neutral position.
sMT00087-00080
2. While holding both the input shaft and countershaft as-

semblies by your hands, install them to the clutch housing.
NOTE:
• Be careful not to damage the Type S oil seal during the
installation of the input shaft assembly.
3. Tighten the input shaft bearing lock plate with the three
bolts.
4. Place the two pieces of the shift lock plates on the clutch sMT00088-00081
housing side.
5. Attach the tension spring to the input shaft bearing lock

plate.
6. Tighten the reverse shift arm with the three bolts.
sMT00089-00082
MT–27
7. Movement of reverse shift arm check
(1) Pull up the reverse shift arm pin with your fingers.
(2) Ensure that the reverse shift arm pin drops smoothly
by its own weight when you release it.
sMT00090-00083
8. Install the reverse idler gear (A), shaft (C) and thrust wash-
er (B) as shown in the right figure.
NOTE:
• When installing, install the slotted spring pin for use in
preventing rotation of the idler gear shaft to the groove (C)
section at the clutch housing side.
• Make sure that the gear chamfer and thrust washer
(nylon) face upward (i.e. rear side). (B)
• Never forget to install the thrust washer (resin made). (A)
ProCarManuals.com
9. Confirmation of length/shape of shift fork and shift fork sMT00091-00084
shaft e w q
(1) The following three shift fork shafts differ in the overall
length, as shown in the right figure.
NOTE:
• Be very careful not to make any wrong installation of
these shift fork shafts.
Shift fork shafts Overall lengths (mm)
q 1st & 2nd 224
w 3rd & 4th 259
e 5th & Reverse 265 sMT00092-00085
e w q
(2) The shift forks and shift heads differ in the external
view, as shown in the right figure. Hence, be very care-
ful not to make any wrong installation of these shift
forks and shift heads.
q 1st & 2nd
w 3rd & 4th
e 5th & Reverse
NOTE:
• It is advisable to install the shift fork shaft and fork tem-
porarily and confirm that the combination and direction sMT00093-00086
are right. Then, proceed to the operation.
10. Installation to shift fork and shift fork shaft

NOTE:
• Apply gear oil to the required points. Perform the oper-
ations, following the procedure given below.
(1) Temporarily drive a new slotted spring pin into all of

the shift forks and heads so that the slotted spring pin
may be driven easily during installation.
sMT00094-00087
MT–28
(2) Install the 3rd & 4th shift fork into the hub sleeve and
insert the 3rd & 4th shift fork shaft.
NOTE:
• Make sure that the gear is in the neutral position.
• In order to drive a new slotted spring pin smoothly, it is
advisable to prepare a guide pin whose outer diameter
is 4.0 mm and whose length is 50.00 mm.
• To perform the operations, while confirming the assem-
bling direction of the shift fork and shift head and the
positional relationship with the gears.
• As for the shapes and lengths of the shift fork shaft, sMT00095-00088
shift fork and shift head, refer to the steps 9 and 10.
• When driving a new slotted spring pin into position, a
measure to sustain the reaction force against the dri-
ving force should be taken at the opposite side of the
shift fork shaft.
ProCarManuals.com
11. Insert a guide pin or the like into the back side groove of
the shift fork, as the guide of installation for the slotted
spring pin.
12. Install a new slotted spring pin.
13. In the same manner as described in the steps 10 and 11,
insert the 3rd & 4th shift head.
14. Install the 1st & 2nd shift fork into the hub sleeve and in-
sert the 1st & 2nd shift fork shaft.
15. As for the installation of 1st & 2nd shift fork and shift head,
refer to the steps 10 and 11 described at the pages
MT–34, 35. sMT00096-00089
16. Insert the 5th & reverse shift head into the shift fork shaft.
17. As for the installation of the 5th & reverse shift fork and
shift head, refer to the steps 10 and 11 described at the
pages MT–34, 35.
18. Attach the tension spring into the reverse shift arm.
sMT00097-00090
19. Install the three balls and compression springs, and tight-
en the three bolts with a new gasket interposed.
NOTE:
• Never reuse the removed gaskets.
20. Install the output shaft assembly with the synchronizer

ring, wave spring and needle roller bearing.
sMT00098-00091
MT–29
21. Clean the contact surface between the clutch housing and
the transmission case side, using scraper and solvent or SIDE VIEW
the like.
22. Apply the following bond to the transmission case surface
as shown in the right figure. (B)
Specified Bond: Three bond® 1217 (A)
[Reference information]
Nozzle Inner Diameter: 0.9 mm
sMT00099-00092
23. Quickly install the transmission case.

24. Tighten the eight bolts from the transmission case side
and the two bolts from the clutch housing side.
25. With the new gasket interposed, tighten the hexagon bolt
(A) for reverse idler gear shaft.
NOTE:
• Never reuse the removed gaskets.
ProCarManuals.com
sMT00100-00093
26. Tighten the rear bearing retainer with the three bolts.
27. Place the transmission magnet (A) and install the new hole
snap ring (B).
28. Install the oil slinger on the countershaft.
sMT00101-00094
29. Clean the contacting surface between the transmission

case and extension housing side, using scraper and sol-
vent or the like.
NOTE:
• Make sure that the oil receiver is installed (tightened)
securely to the inside of the extension housing. (A)
30. Apply the following bond to the extension housing surface

as shown in the right figure.
Specified Bond: Three Bond® 1217
[Reference information] sMT00102-00095
Nozzle Inner Diameter: 0.9 mm

SIDE VIEW
31. Quickly install the extension housing together with engine
rear mounting bracket. Then, tighten it with the eight bolts.
Tightening Torque: 29.4 - 44.1 N·m (B)
(A)
32. Install the speedometer sleeve assembly.
33. Tighten the speedometer gear lock plate with the bolt.
sMT00103-00096
MT–30
34. Install the clutch related parts.
NOTE:
• Refer to the CL section. (B)
(A)
35. Install the reverse restrict cam (A) and shift lever (B) as
shown in the right figure with torsion spring and the re-
verse restrict shaft.
CAUTION:
• Ensure that the reverse restrict cam is installed correct-
ly. Failure to observe this caution would cause disen-
gagement of the reverse gear. sMT00104-00097
36. Tighten the bolt with a new gasket interposed for the re-
verse restrict shaft.
37. Install the shift lever boot and shift lever shaft correctly as
shown in the right figure.
CAUTION: (A)
• Ensure that the air bleeding section (A) of the boot
faces toward the lower side.
ProCarManuals.com
sMT00105-00098
38. With a new gasket interposed, tighten the select lever (C)
shaft subassembly with the four bolts.
NOTE:
• Ensure that the reamer bolts (C) are placed as shown
39. Install the ball and compression spring and tighten the re-
verse restrict pin holder (B) with a new gasket interposed.
Tightening Torque: 29.4 - 49.0 N·m sMT00106-00099
40. Ensure that the select lever,shift lever and gears move
smoothly.
MT–31
APPENDIX
SSTs (Special Service Tools)
Shape Part No. and name Use
09306-87602-000
Removal of bearing
Puller
09308-00010-000
Removal of oil seal
Oil seal puller
09310-87302-000
Assembling of bearing
Transmission bearing replacer
09334-87301-000 Removal of gear, bearing

ProCarManuals.com
and
Transmission rear bearing anvil synchronizer hub assembly
09351-32070-000
(Component of 09350-32014-000) Removal of sub gear
Piston spring compressor
09950-20017-000 Removal of gear, bearing

and
Universal puller synchronizer hub assembly
sMT00107-00100
MT–32
SERVICE SPECIFICATIONS
Item Specified value Allowable limit
Free length 24.00 —
Free length of
compression spring for Load as installed: N (kgf) 28.83 (2.43) —
reverse restrict pin
Height as installed: 17.00 —
Free length 40.00 —
Free length of
compression spring for Load as installed: N (kgf) 47.33 (4.83) —
shift fork shaft
Height as installed: 30.00 —
+0
Outer Reverse idler gear shaft 20.0 –0.013 —
Diameter +0.061
Inner Reverse idler shaft 20.0 +0.032 —
–0.02
Outer Select inner lever 15.0 –0.12 —
+0.1
Inner Shift inner lever 15.0 +0.2 —
–0.05
Outer Shift fork shafts 13.0 –0.08 —
Inner Case sides 13.0 +0.043
+0 —
Dimensions –0.02
Outer Shift inner lever 12.0 –0.12 —
+0.1
Inner Shift heads 12.1 +0 —
–0.065
Outer Reverse restrict shaft 8 –0.090 —
+0.16
ProCarManuals.com
Inner Reverse restrict cam 8 +0.07 —

Clearance between synchronizer ring and gear 0.9 - 1.4 0.5
sMT00108-00000
AT THE INPUT SHAFT SIDE

Contact width section between shift Shift forks 3rd & 5th 7 –0.1
–0.3 6.6
forks and synchronizer No. 2 & No. 3 +0.12
hub sleeves Hub sleeves 3rd & 5th 7 +0.05 7.2
3rd 0.10 - 0.52 —
Thrust clearance
5th 0.10 - 0.40 —
Clearance between synchronizer rings and gears 0.95 - 1.35 0.90
(A) and (B) 32 –0.009
–0.029 —
Outer diameter of input shaft –0.016
(C) 20 –0.034 —
Classification Identification — —
Outer diameter of No. 2 Yellow 57.78 - 57.84 —

hubs No. 1 None 57.68 - 57.74 —
Dimensions No. 3 White 57.58 - 57.64 —
No. 2 Yellow 57.87 - 57.97 —
Inner diameter of
No. 1 None 57.77 - 57.87 —
hub sleeves
No. 3 White 57.67 - 57.77 —
No. 2 18.55 ± 0.03 —
Thickness of synchronizer hubs
No. 3 12.40 ± 0.03 —
+0.05
Thickness of transmission hub sleeve stopper 7.2 –0.01 —
+0.025
Inner diameter 3rd and 5th gears 37.0 +0 —
Dimensions 3rd gear 37.95 ± 0.03 —
Thickness
5th gear 27.85 ± 0.03 —
–0.2
Height of synchromesh shifting key 5 –0.4 —
End play between the snap ring shaft and input shaft 0 Less than 0.16
sMT00109-00000
MT–33
AT THE COUNTER SHAFT SIDE
+0.12
Contact width section between the synchronizer No. 1 hub Hub sleeve 10 +0.05 10.2
sleeves and 1st/2nd shift fork Shift fork 10 –0.3
–0.1 9.6
1st 0.10 - 0.56 —
Thrust clearance between gear and counter shaft
2nd 0.10 - 0.44 —
Height of shifting key 5.1 ± 0.1 —
–0.009
Outer diameter of counter shaft (A) and (B) 32 –0.029 —
Thickness of 1st gear thrust washer 4 ± 0.03 —
Classification Identification — —
Outer diameter of No. 2 Yellow 69.78 - 69.84 —
synchronizer No. 1
hub No. 1 None 69.68 - 69.74 —
Dimensions No. 3 White 69.58 - 69.64 —
No. 2 Yellow 69.87 - 69.97 —
Inner diameter of
synchronizer No. 1 No. 1 None 69.77 - 69.87 —
hub sleeves
No. 3 White 69.67 - 69.77 —
+0.025
Inner 1st and 2nd gear 37.0 +0 —
ProCarManuals.com
Dimensions 1st 27.27 - 27.37 —

Thickness
2nd 36.23 - 36.33 —
Height of conical spring washer 2.01 1.04
End play between the snap ring shaft and counter shaft Less than 0.16
sMT00110-00000
TIGHTENING TORQUE
Tightening components N·m kgf-m
Lock nut × Output shaft 177.0 - 216.0 18.0 - 22.0
Reverse restrict pin holder × Transmission case 29.4 - 49.0 3.0 - 5.0
Transmission case cover × Transmission case 14.7 - 21.6 1.5 - 2.2
Bolt for reverse restrict shaft × Transmission case 18.6 - 30.4 1.9 - 3.1
Speedometer lock plate × Extension case 6.9 - 9.8 0.7 - 1.0
Clutch housing × Transmission case 14.7 - 21.6 1.5 - 2.2
Transmission case × Extension housing 29.4 - 44.1 3.0 - 4.5
Extension housing × Filler & Drain plugs 29.4 - 49.0 3.0 - 5.0
Input shaft bearing lock plate × Clutch housing 14.7 - 21.6 1.5 - 2.2
Reverse shift arm × Clutch housing 14.7 - 21.6 1.5 - 2.2
Bolt for shift fork shaft × Clutch housing 18.6 - 30.4 1.9 - 3.1
Rear bearing retrainer × Transmission case 14.7 - 21.6 1.5 - 2.2
Engine rear mounting bracket × Extension housing 29.4 - 44.1 3.0 - 4.5
Direct connecting bolt × Transmission 49.0 - 68.6 5.0 - 7.0
Propeller shaft × Differential companion flange 39.2 - 53.9 4.0 - 5.5
Control cable bracket 14.7 - 21.6 1.5 - 2.2
Transmission floor shift assembly × Body 9.8 - 15.7 1.0 - 1.6
sMT00111-00000
TO INDEX TO NEXT SECTION

DAIHATSU TYPE M5S Series Manual Transmission 9233

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DAIHATSU TYPE M5S Series Manual Transmission 9233

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SECTION INDEX

SECTION NAME SECTION

IMPORTANT SAFETY NOTICE ...................... GI–2

IMPORTANT SAFETY NOTICE

for experienced service personnel.

WARNINGS, CAUTIONS AND NOTES

The following list describes general WARNINGS:

29.4 - 49.0 : Tightening torque

9. Confirmation of length/shape of shift fork and shift fork

3. Handling instructions related to battery.

TO INDEX TO NEXT SECTION

OUTLINE ................................................... MT– 2 COUNTERSHAFT ................................ MT–18

Reverse idler gear

Counter gear shaft

Reverse gear Transmission case

18.6 - 30.4 6.9 - 9.8 @6

q Clutch housing !6 5th & reverse shift fork shaft

q Torsion spring @1 Shaft snap ring

q Shaft snap ring !2 Needle roller bearing

q Shaft snap bearing !1 Synchronizer No. 1 hub assembly

1. Remove the clutch-related parts.

5. Remove the hexagon bolt (A) of the reverse idler gear

sure to drive off the pin, working from the underside,

7. Remove the reverse restrict cam (A), torsion spring (B)

Disassembly of transmission case

1. Pull out the oil slinger from the countershaft.

3. Remove the bearing retainer.

Removal of shift fork

1. Detach the tension spring (A).

Removal of input shaft and counter shaft

sembly by your hands, pull out them in such a way that

2. Visually inspect the balls for deformation or scratches.

3. Measure the contact width section between the select

2. Measure the contact width section between the shift

Reverse idler gear

d (Reverse idler gear) D (Shaft)

REPLACEMENT OF TYPE S OIL SEAL

it would cause oil leakage. Therefore, be certain to re-

4. Apply lithium based MP grease to the lip section of the

SHIFT LEVER & SHIFT RELATED PARTS

4. Check that continuity exists at the backup lamp switch as-

specification above, proceed to disassemble the input sMT00028-00026

4. Remove the following parts, using the following SST.

(1) Synchronizer No. 2 hub assembly

5. Remove the needle roller bearing.

(1) Synchronizer No. 3 hub assembly

10. Remove the split type needle roller bearing. (B)

11. Remove the selection type shaft snap ring.

2. Measure the outer diameter of the input shaft at the sec-

5. Measure the thickness of the synchronizer hub No. 2 (C)

6. Measure the height of the transmission hub sleeve stop-

7. Measure the thickness (L) and inner diameter (D) of the

8. Measure the height of the synchromesh shifting key.

9. Visually inspect the synchromesh shifting key spring for

• During the split type needle roller bearing installation,

2. Install the 5th gear and synchronizer ring to the input

4. Ensure that the grooved section in the protrusion position

5. Install the transmission hub sleeve stopper.

90045-22265 1.98 Blue 90045-20269 1.82 None